Apparatus for packing objects in a carton

ABSTRACT

Apparatus for packing a plurality of objects, such as, reams of paper, in a carton which, includes; means for moving a single layer of the objects onto a retractable elevator plate; means for lowering the elevator plate the height of one layer of objects; first transfer means for transferring a pre-determined stack of the objects from the elevator plate to another plate, where two sides of the stack of objects are squared by the first transfer means and a backup plate; second transfer means for moving the objects onto a cartoning plate; retractable stop plate means positioned on the opposite side of the second transfer means and together with the second transfer means adapted to square the other two sides of the object; means for removing a folded carton from a carton rack and simultaneously breaking the carton to form it into a generally tubular configuration with top and bottom flaps open; means for lowering the carton over the stack of objects; means for breaking one flap of the carton outwardly and means for spreading the opposite two corners of the bottom flaps, thereby causing the other three flaps to open outwardly and to form a funnel with the first mentioned flap as the carton is lowered over the stack of objects; means for applying glue to two of the bottom flaps; and means for folding the bottom flaps. Means are also provided for adding a flat filler to the bottom of the stack of objects prior to cartoning and means are provided for detecting the height of the stack of objects in the carton, determining the number of flat fillers necessary to fill the carton and filling the carton with the determined number of fillers.

United States Patent [1 1 Feurston et al.

[ 1 Sept. 11, 1973 APPARATUS FOR PACKING OBJECTS IN A CARTON [76] Inventors: Ludwig J. Feurston; Frederick F.

Koehn, both of Box 715, Sheboygan, Wis.

[22] Filed: Feb. 10, 1972 [21] Appl. No.: 225,086

Sabel 53/242 X Primary ExaminerRobert L. Spruill Att0rneyFred C Philpitt [57] ABSTRACT Apparatus for packing a plurality of objects, such as, reams of paper, in a carton which, includes; means for moving a single layer of the objects onto a retractable elevator plate; means for lowering the elevator plate the height of one layer of objects; first transfer means for transferring a pre-determined stack of the objects from the elevator plate to another plate, where two sides of the stack of objects are squared by the first transfer means and a backup plate; second transfer means for moving the objects onto a cartoning plate; retractable stop plate means positioned on the opposite side'of the second transfer means and together with the second transfer means adapted to square the other two sides of the object; means for removing a folded carton from a carton rack and simultaneously breaking the carton to form it into a generally tubular configuration with top and bottom flaps open; means for lowering the carton over the stack of objects; means for breaking one flap of the carton outwardly and means for spreading the opposite two corners of the bottom flaps, thereby causing the other three flaps to open outwardly and to form a funnel with the first mentioned flap as the carton is lowered over the stack of objects; means for applying glue to two of the bottom flaps; and means for folding the bottom flaps. Means are also provided for adding a flat filler to the bottom of the stack of objects prior to cartoning and means are provided for detecting the height of the stack of objects in the carton, determining the number of flat fillers necessary to fill the carton and filling the carton with the determined number of fillers.

2 Claims, 14 Drawing Figures PATENTED I I975 sum osnr1o FIG. 5.

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PATENTEB SEN I I975 sum as ur1o M M 6 v 5 fif m 5 PATENTED SEN 1 I975 snail-canno FIG. 9.

PATENTED SEN I i973 SMET 09 0f 10 man O PO m APPARATUS FOR PACKING OBJECTS IN A CARTON BACKGROUND OF THE INVENTION The present invention relates to an automatic apparatus for packing a plurality 'of objects in a carton. More specifically, the present invention relates to apparatus for packing generally rectangular objects in a carton which includes means for lowering a generallytubular carton over a stack of objects and simultaneously spreading the lower flaps of the carton into an object-receiving funnel configuration.

DESCRIPTION OF THE PRIOR ART In the prior art, a number of devices have been designed for packing objects in a carton. Most of these devices require at least some manual labor to place the objects in the carton from the top. In other devices, the objects are forced into the carton from the bottom mechanically or are forced into the carton from the side mechanically. There are numerous disadvantages to these types of operations in that they require rather complicated mechanisms or that they are only semiautomatic in operation. In addition, in those instances in which the objects are sealed packages and the objects are lifted by hand, the seals on the packages can be readily broken open.

SUMMARY OF THE INVENTION In accordance with the present invention, a plurality of objects are packed in a carton by moving a generally tubular carton downwardly over the objects while spreading the lower flaps of the carton into an objectreceiving funnel configuration.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be described with reference the drawings wherein;

FIG. 1 is an isometric view of the overall apparatus of the present Application. showing the major hydraulic and pneumatic cylinders which operate the mechanism and the locations of the major switches which actuate the various hydraulic and pneumatic systems;

FIG. 2 shows systematically the hydraulic and pneumatic cylinders of the system together with the major solenoid means whichoperate the hydraulicand pneumatic cylinders;

FIGS. 3A and 3B is an electrical schematic of the systern;

FIGS. 4 and 5 show in greater detail the flap spreading mechanism of the apparatus;

FIG. 6 is an isometric view, partially in section of a modified infeed indexing system;

FIG. 7 is an electrical schematic of the modification of FIG. 6.

FIGS. 8 and 9 are side and top views, respectively, of a bottom filler system;

FIGS. 10 and 11 are side and front views, respectively, and

FIGS. 12 and 13 are top and side views, respectively, of a top filler system.

In describing the apparatus of the present invention, it is best to describe the sequence of operation along with the components of the system.

In accordance with FIGS. 1, 2, and 3 of the drawings, the sequence of operations is first started by closing air pressure switch contacts 202 and a series of manual switches to actuate the system and start the machine in operation. Specifically, a master control switch 204 is turned on to energize the control circuit. A manual motor starter (not shown) is turned on to start vacuum pump 2. Also, a carton elevator switch 206 is turned on. An impulse counter 212 is associated with the stack elevator cylinder 4. This impulse counter counts the number of layers of packages to be loaded in the carton, and an index knob thereon can be adjusted to change the number of layers of packages to be loaded. A manual start cycle switch 201 is then depressed to start the automatic cycle in operation.

With the machine properly adjusted and proper air pressure available, the machine is ready to receive packages. Manual motor starters are turned on to start infeed conveyor 6 in operation. A package is advanced from a position (not shown) perpendicular to infeed conveyor 6 and onto a dead plate at the end of infeed conveyor 6. As the package is pushed from the dead plate across the front end of infeed conveyor 6, limit switch 8 is actuated and this, in turn, energizes extender solenoid 10 which, in turn, extends orienting pusher cylinder 12. The pusher 12 advances a single package onto infeed conveyor 6. When the orienting pusher 12 is extended, limit switch 14 assumes a normally closed position and orienting retract solenoid 16 is energized to retract orienting pusher 12 and thereby place it in position to receive another package.

Infeed conveyor belt 6 advances the package onto infeed transfer plate 20 in front of infeed transfer cylinder 18, thereby contacting stop plate 24, mounted on infeed transfer plate 20 and actuating limit switch 22, mounted on stop plate 24. At this point in the sequence, limit switch 26, associated with infeed transfer cylinder 18, is held in its closed position by infeed transfer cylinder 18 in its retracted position. At the same time, limit switch 28, mounted on end plate 36,

is held in its closed position by tamping plate 30 and tamping cylinder 32, when tamping cylinder 32 is in its retracted or upper position. Finally, limit switch 34 on end plate 36 is in its normally closed position. With these three switches (26,28 and 34) in their closed positions, extender solenoid 38, associated with transfer cylinder 18, is energized to advance two packages onto elevator plate 40 which is mounted on the top of stack elevator cylinder 4. As the package is advanced onto the elevator plate 40, limit switch 34 is opened by the packages and limit switch 26 is permitted to close..The opening and closing of these two switches in turn energize retract solenoidv 39, thereby retracting infeed transfer cylinder to receive another set of packages.v

With the two packages on elevator plate 40, and limit switch 26 closed, as previously indicated, extender solenoid 42 is energized, thereby extending tamping cylinder 32. Tamping cylinder 32 pushes the packages down below infeed transfer plate 24 and momentarily closes limit switch 44, mounted on the frame holding tamping plate 30 and cylinder 32. The actuation of limit switch 44 energizes solenoid 46 thereby retracting tamping cylinder 32. Limit switch 44, in turn, momentan'ly energizes a pulse motor 210 in the counter 212 causing it to count the package. Tamping plate 30 and cylinder 32 also serve to press-air out of packages, such as reams of paper which tend to trap air between the sheets of paper, and thereby facilitate the cartoning of the packages. When solid objects are tobe cartoned, tamping plate 30 and tamping plate cylinder 32 may be eliminated along with their associated limit switches 26 and 28. A solenoid-operated hydraulic valve can then be actuated by switch 34 to lower elevator plate 40 a distance equal to one layer of packages.

Single layers of packages are sequentially pushed down on the elevator by tamping cylinder 32 until the desired count is reached. This then closes a set of contacts 214 in the counter. A control relay 216 is energized and a set of contacts 218 open to prevent infeed transfer cylinder 18 from operating after the desired count has been reached. Another set of contacts 220 are then closed, energizing hydraulic valve solenoid 48, associated with stack elevator cylinder 4, and stack elevator retract solenoid 50, thereby lowering the elevator. Hydraulic reservoir control cylinder 52 acts as a reservoir for fluid from stack elevator cylinder 4, and, of course, when the stack elevator cylinder 4 is in its lowermost position, cylinder 52 discharges its fluid to raise the stack elevator cylinder. With the elevator fully retracted, limit switch 54, on the frame of the apparatus, is closed, thereby energizing a control relay 222 and closing contacts 224. In this mode, limit switch 56 is actuated, thereby indicating that stack transfer cylinder 58 is retracted. At the same time, extender solenoid 60 is energized, thereby activating stack transfer cylinder 58 and extending the stack transfer cylinder. Stack transfer cylinder 58 then pushes the stack of packages off elevator plate 40 onto table 62 and against backup plate 64. Backup or stop plate 64 carries limit switch 66, which deenergizes control relay 216 which, in turn, closes a set of contacts 226. Limit switch 68, operated by elevator plate 40, is now in its normally closed position, thereby energizing retract solenoid 70 which retracts stack transfer cylinder 58. A set of contacts 228 are now closed and limit switch 68 remains in its closed position, as a result of elevator plate 40 in its lowermost position, thereby energizing control relay 222 and also energizing extender solenoid 74, associated with elevator cylinder 4, and solenoid 76, associated with stack elevator hydraulic cylinder 50. Energizing solenoids 74 and 76 raises the elevator to its uppermost position. With the elevator in its raised position, limit switch 78 is actuated by the elevator plate 40 in its uppermost position, thereby deenergizing the last mentioned control relay 222 and the elevator is held in its uppermost positionby a hydraulic check valve.

With a stack of packages against stop plate 64, limit switch 66 is actuated, as previously indicated. With carton elevator cylinder 80 in its uppermost or extended position closing limit switch 230, the stack transfer cylinder 58 is in its retracted position, thereby actuating limit switch- 84 and closing a set of contacts 232, thereby energizing extender solenoid 86, associated with transfer cylinder 88, and extender solenoid 90, associated with retractable stop cylinder 92. Solenoid 86 extends transfer cylinder 88 to push the stack of packages onto cartoning table 96, and solenoid 90 extends retractable stop cylinder 92 to press stop plate 94 against the stack of packages to square up and locate the leading edge of the stack of packages. As the stack is transferred from the position'against stop plate 64 onto cartoning table 96, limit switch 66 assumes its normally closed position and limit switch 98 is actuated, thereby energizing a control relay 234 and a set of contacts 236 to energize retract solenoid 100. Solenoid 100 retracts transfer cylinder 88 and closes a set of contacts 238 to energize retract solenoid 102 which is associated with retractable stop cylinder 92, thereby retracting retractable stop plate cylinder 92 to move stop plate 94 away from the stack as shown in the drawing. The stack of packages is now in position for canonmg.

When the master control switch was turned on, limit switch 104, associated with carton elevator cylinder 80, was closed thereby energizing extender solenoid 106. Solenoid 106 is associated with carton elevator cylinder and raises the carton elevator. Just before the elevator reaches its uppermost extended position, limit switch 107 is actuated and vacuum bar retract solenoid 108 is actuated. Vacuum bar solenoid 108 is associated with vacuum bar cylinder 110. Vacuum bar cylinder 110 and carton elevator cylinder 80 are connected rigidly together (not shown) so that the vacuum bar cylinder 110 is lowered and raised by the carton elevator cylinder 80. With solenoid 108 energized, vacuum bar cylinder 110 is extended. Also, when carton elevator cylinder 80 reaches its uppermost, extended position, it actuates a limit switch 240 which energizes flap spreader finger, extender solenoid 112, thereby extending flap spreader fingers 114. Obviously, a pair of such flap spreader fingers are present adjacent the two front comers of the carton. Spreader fingers 114 are associated with flap spreader cylinders 116. As the vacuum bar 118, connected to vacuum bar cylinder 110, extends to pick up a carton from the carton storage rack, limit switch is actuated. Limit switch 120 energizes vacuum solenoid 122, which creates a vacuum in the vacuum cups of vacuum bar 118, and energizes a control relay 242, thereby opening a set of contacts 244 and deenergizing retract solenoid 123. Solenoid 123 is associated with trailing flap cylinder 124, thereby retracting the trailing flap cylinder. When the vacuum bar cylinder 110 is fully extended, it actuates limit switch 126, thereby energizing retract solenoid 128. Solenoid 128 serves to retract vacuum bar cylinder 110. Limit switch 126 also energizes solenoid 130, associated with carton hopper inching cylinder 132. Carton hopper inching cylinder 132 serves to advance the stack of cartons, to position the next folded carton for subsequent pickup. Limit switch 126 also energizes retract solenoid 134. Solenoid 134 is associated with transfer gate cylinder 136 and retracts transfer gate cylinder 136. As vacuum bar cylinder 1 l0 retracts, it actuates limit switch 138. Limit switch 138 energizes extender solenoid 140, thereby extending trailing flap cylinder 124. As the vacuum bar cylinder 110 retracts to pull a carton blank from the rack, stationary plate 141 breaks the carton at its right front corner and forms a tubular carton with its top and bottom flaps open. The extension of trailing flap cylinder 124 tends to break the rear-most flap of the carton upwardly so that, once broken, it will remain in a generally-horizontal position thereafter. When vacuum bar cylinder 1 10 is retracted, it actuates limit switch 107, thereby energizing retract solenoid 142. Solenoid 142, is associated with carton elevator cylinder 80 and lowers the elevator cylinder 80. As the elevator cylinder 80 is lowered, it actuates limit switch 144. Limit switch 144 energizes retract solenoid 146. Solenoid 146 is associated with flap spreader cylinders 116 and thereby retracts spreader finger cylinders 116 to slightly open the three flaps in contact with fingers 114 and guide the carton over the stack of packages. When the elevator cylinder 80 reaches its lowermost position, it actuates limit switch 148. At the same time, the front carton flap actuates limit switch 150, thereby energizing extender solenoid 152. Solenoid 152 is associated with transfer gate cylinder 136, thereby extending the transfer gate cylinder 136. Limit switch 154 is closed when transfer gate cylinder 136 is in its uppermost position. Limit switch 154 energizes extender solenoid 108. Solenoid 108 is associated with vacuum bar cylinder 110 and serves to extend vacuum bar cylinder 110. The extension of vacuum bar cylinder 110 transfers the case over a transfer gate (not shown) mounted on cylinder 136, and folds the two bottom flaps which are oriented in the same direction of motion, by means of a stationary, generally V-shaped, slotted flap folder (not shown) located behind the transfer gate on cylinder 136 and forming the slots with the rear portion of the transfer gate. As this transfer takes place, the vacuum bar 118 opens limit switch, 156, thereby deenergizing control relay 234 and opening limit switch 158. The opening of limit switch 158 deenergizes vacuum solenoid 122, thereby releasing the vacuum bar 118 from the carton. The case is now against stop plate 160 where it actuates limit switch I62. Limit switch 162 energizes retract solenoid I28. Solenoid 128 is associated with vacuum bar cylinder 110 and therefore retracts vacuum bar cylinder 1 10. When fully retracted, vacuum bar cylinder 1 actuates limit switch 104, thereby energizing extender solenoid 106. Solenoid 106 is associated with carton elevator cylinder 80 and therefore extends the carton elevator cylinder 80 and moves it to uppermost position ready for the start of the carton pickup sequence.

A case against stop plate 160 also closes a second set of contacts in limit switch 162, which are wired in series with limit switch 164. When the discharge carriage cylinder 168 is extended, it actuates limit switch 164, thereby energizing extender solenoid 166. Solenoid 166 extends discharge transfer cylinder 168. Limit switch 164 also energizes extender solenoid 144. Solenoid 144 extends discharge finger cylinders 172, thereby'raising the discharge finger cylinders. When the discharge finger cylinders 172 are extended, they actuate limit switch 174, thereby. energizing retract solenoid 176. Solenoid 176 is associated with discharge cylinder 168 and retracts discharge cylinder 168. The discharge cylinder 168, when in its retracted position, actuates limit switch 180. Limit switch 180 energizes retract solenoid 120. Solenoid 120, in turn, retracts discharge finger transfer cylinder 168. Limit switch 180 also energizes retract solenoid 184, which retracts transfer finger cylinders 172. Finally, limit switch 180 actuates extender solenoid 148, thereby extending discharge carriage cylinder 168. Transfer finger cylinders 172 and discharge cylinder 168 continue to cycle in time with each other to continuously advance the carton. Discharge finger transfer cylinder 168 remains in a retracted position until another carton is against stop plate 160 and discharge cylinder 168 is in a proper position for cylinder 168 to extend.

The case being discharged from the position against stop plate 160 actuates limit switch 186. Limit switch 186 energizes glue skip extendersolenoid 188. Glue skip solenoid 188 is associated with glue skip cylinders 190. Glue skip cylinders 190 areextended to thereby apply glue to the two large flaps of the case. The case moving further down the discharge table actuates limit switch 192. Limit switch 192 deenergizes glue skip solenoid 188. Then, as the case moves further down toward "the end of the discharge table, the two large flaps, to which glue has been applied, are then folded underneath to close the bottom of the carton by means of the slot formed between the discharge table and broader table extension 193. The carton is then discharged to a loading or other area.

If oil in the hydraulic system reaches a low level, the hydraulic reservoir rod actuates limit switch 244 energizing control relay 246, contacts 248 of a hold circuit and indicating light 250 will remain on.

If master control switch 204 is turned off, the impulse counter will reset. After switch 204 is turned on, manual count switch 252 is depressed to correspond to the number of packages on the stacking elevator to bring the counterback to the original count.

FIGS. 4 and 5 of the drawings show a detailed view of the flap spreader mechanism. In accordance with FIGS. 4 and 5, the flap spreader mechanism is provided with an appropriate support 194. Support 194 has pivotally attached thereto, by means of pivot 196, flap spreader fingers 114. Pivoted to flap spreader finger 114 by means of pivot 198 is flap spreader cylinder 116. The opposite end of cylinder 116 is pivotally mounted to frame 194 by means of pivot 200.

In accordance with FIGS. 6 and 7 of the drawings, the machine is properly adjusted, proper air pressure is supplied and the motor starter for the infeed conveyor is on. This procedure is the same as the previous embodiment. However, in accordance with the embodiment of FIGS. 6 and 7, a different infeed indexing system is utilized to transfer a package from the infeed conveyor 6 to elevator plate 40. This infeed indexing system is a preferred embodiment where incompressable objects are being stacked, and there is no need for the tamping device. Specifically, conveyor belt 6 advances a package to infeed indexing overhead 254, thereby actuating limit switch 22. Limit switch 22 energizes control relay 256 closing contacts 258 and energizing overhead clutch 260. The energization of overhead clutch 260 causes infeed indexing overhead 254 to transfer a package onto the stack elevator plate 40. Also, when control relay 256 is energized, contact 262 is closed, thereby energizing impulse counter 212.

Packages being pushed onto stack elevator 40 actuate limit switch28 and limit switch 34, thereby energizing control relay 264 and closing contacts 228. The closing of contacts 228 energizes solenoid 76, lowering stack elevator '40 until packages thereon release limit switch 28 and limit switch 34, and the elevator is stopped. When the desired count is reached, contacts 214 in inpulse counter 212 are closed. Control relay 216 is energized and contacts 218 open to prevent indexing overhead 254 from operating afier the count is reached. Contact 266 and contact 268 are closed, thereby energizing solenoid 50 and lowering elevator 40. With elevator 40 fully retracted, limit switch 54 is closed, thereby energizing control relay 222, closing contacts 224 and actuating limit switch 56. This sequence indicates that transfer cylinder 58 is retracted. When the transfer cylinder is, thus, retracted, solenoid 60 is energized actuating the stack transfer cylinder 58, advancing the stack off elevator 40 against stop plate 64, which, in turn, actuates limit-switch 66, deenergizes control relay 216 and closes contacts 226. Limit switch 84 is now in its normally closed position, thereby energizing solenoid 70, and retracting stack transfer cylinder58. Contacts 228 are now closed, and limit switch 68 is closed by stack transfer plate 74 in its retracted position, thus energizing control relay 222 and solenoid 74 to raise elevator 40.

FIGS. 8 and 9 of the drawings show an apparatus for depositing a flat, preferably corrugated, filler in the bottom of the carton beneath the articles to be cartoned. The bottom'filler apparatus is mounted in the system adjacent elevator table 40. FIG. 8 shows a side view and FIG. 9 a top view of the bottom filler system. The fillers are loaded into a magazine shown to the right of FIG. 8. Specifically, FIG. 8 shows back frame section 270 and front frame section 272. Mounted between these frame sections, near the bottom thereof, are a pair of L-shaped channels 274. Channels 274 are spaced on either side (front and rear) of FIG. 8 to support the bottom of the filler standing edgewise in the magazine. One of the channels 274 is slidably adjustable backward and forward to accommodate different sizes of fillers. This is accomplished by mounting channels 274 slidably on supports 276 and 278 respectively. Support 278 has a slot therein and a bolt 280 passes through this slot to lock the channel at the appropriate position along support 278. Mounted adjacent the top of supports 270 and 272 is a cylindrical bar 282. Slidably mounted on cylindrical bar 282 by means of bearings 284 is backup plate support 286. Mounted on backup plate support 286 is backup plate 288 having weight 290 thereon. Accordingly, the backup plate assembly is slidable along bar 282 by gravity and applies sufficient pressure to the back of a stack of fillers to hold them forward in the magazine. The front filler is held in place by means of knife blades 292 and 294 respectively. A bar 296 is mounted on backup plate support 286. When the backup plate assembly is moved to the right, bar 296 engages a notch in bar 298 to hold the backup plate assembly while additional fillers are put into the magazine. Mounted across front supports 272 is a cross plate 300 which is adjustable upwardly and downwardly by means of hand wheel 302 to apply slight pressure to the top of the fillers in the front of the magazine and adjust the position of knife blade 292. Connected to front supports 272 of the magazine and upright support 304 is support frame 306. Support frame 306 has mounted therein cam tracks 308. Cam tracks 308 support a csrriage 310 having bearings 312 attached thereto and cooperating with cam tracks 308. With one end attached to frame 306 and its rod attached to carriage 310 is pneumatic or air cylinder 314. Pneumatic cylinder 314 moves carriage 310 backwardly and forwardly in the frame 306. Pivotally mounted in carriage 310 is support member 315. Support member 315 has passing therethrough and rigidly attached thereto suction cup unit 316. Also rigidly mounted on support member. 315 is cam support 317. Cam support 317 carries cam roller 318. Mounted on frame 308, in line with cam roller 318, is cam track 310. Below frame 306 is table 322. Mounted adjacent one side of table 322 is pivotal guide member 324. Mounted adjacent table 322, beneath the magazine, is hydraulic cylinder 326, whose rod and a pusher plate 328 can be extended across table 322 to the edge of table 40.

In operation, the system of FIGS. 8 and 9' removes a filler from the tiller magazine and drops it on the table 322, and it is then pushed onto elevator table 40. Specifically, fillers are loaded into the magazine with backup plate 288 behind the stack. The front filler in the stack is held in place by knife blades 292 and 294 and suction cups of suction cup means 316. Upon rcceipt of an electrical signal calling for the deposit of a filler, the vacuum is turned on in vacuum cup means 316. At the same time, cylinder 314 is actuated to produce a 7 inch stroke extending the rod of the cylinder. During the first 3 inches of the stroke of cylinder 334, the carriage 310 is moved rearwardly, and suction cup means 316 pulls the filler from the magazine and outwardly a distance of 3 inches. At this time, cam 318 strikes cam track 320. Cam 318 then moves upwardly along cam track 320 during the next 4 inches of travel of the rod of cylinder 314. As cam 318 moves upwardly on cam track 320, cam support 317 is turned through thereby also pivoting aupport 315 and suction cup means 316 through 90. At the end of the stroke of cylinder 314, a signal is given to shut off the vacuum of vacuum cup means 316, thus dropping the filler onto table 322. The vacuum cup means, along with carriage 310, is then moved back to its initial position, ready to pick up and deposit another filler. Cylinder 326 is then actuated and extends for a 24 inch stroke across table 22, and the filler is pushed from table 22 by means of plate 328 and thence onto the stack elevator plate 40. At this time, the elevator plate 40 is in position to re ceive the filler and thereafter the stack of objects being cartoned.

FIGS. 10 and 11 illustrate a system for detecting the height of product in the carton, automatically measuring the number of flat filler elements needed to fill the box and transmitting a signal to the hereinafter described filler discharge system. The present system for detecting the number of fillers necessary is located to the rear of the discharge table of FIG. I, just after the carton has been moved onto the discharge table. The detecting system is mounted on frame 330. Mounted between the sides of frame 330 are tubular slide ways 332. Slidably mounted on tubular slide ways 332 is support 334 for mounting plate 336. Mounted on mounting plate 336 is the detecting system specifically referred to hereinafter. Also, slidably mounted on tubular slide ways 332 is support 338 for the probe system. Extending from support 338 is support 340 carrying probe 342. Between the shaft 344 of probe 342 and the support beam 340 is a spring 346 which urges support 340 upwardly. As the carton is moved into position under probe 342, a switch 348 on the discharge table is activated by the box causing the cylinder 350 to bring the probe down onto the product in the carton. The height of the probe system may be present manually by moving supports 338 and 340 downwardly to a predetermined filled height for the carton. The predetermined position is then maintained by locking collar 352 on the shaft 344 of probe 342 and the collar 354 on the shaft of hydraulic cylinder 350. As cylinder 350 moves the probe downwardly, the support 338 also moves an actuating arm 356 downwardly. Actuating arm 356 is fixedly attached to chain 358. As actuating arm 356 moves downwardly, it drives chain 358 which passes over free-running gear 360 and gear 362. The tension of chain 358 may be adjusted by means of chain take-up bracket 364 which presses gear 366 against chain 358. Rigidly mounted on gear 362 is registration disk 368. Registration disk 368 is provided with registration holes 370. Registration holes 370 are spaced around disk 368 such that each hole represents the thickness of one flat filler element. Accordingly, as the probe moves downwardly, chain 358 is driven by actuating arm 356, thereby rotating disk 368. Mounted behind disk 368 is a light source 372 for an electric eye. On the opposite side of plate 368 is an electric eye detecting element 374 for counting the number of pulses each time a hole is detected by the electric eye system. These pulses are then transmitted to the hereinafter described filler system. Accordingly, a pulse is transmitted for each hole in the disk and therefore for each filler needed in order to bring the height of the material within the carton to the pre-determined set height previously mentioned. The electric eye system is adjustable to accommodate varying thicknesses of fillers. Specifically, plural row of holes 370 on the disk are spaced different distances apart so that each row represents a particular thickness of filler. In order to change the detection system to accommodate different thicknesses of filler, bracket 376, carrying the electric eye system, is simply moved downwardly on support plate 336 or upwardly as desired. IN order to accommodate different heights of cartons, the detecting system may be moved upwardly and downwardly by means of support 334. Support 334 is attached to the end of screw rod 378. Screw rod 378 passes through a cross member of the frame 330. The system is also provided with an alarm which is actuated by switch 380 mounted adjacent the upper end of probe rod 346 and actuated by collar 382 on the probe rod. If the product in the carton is below a pre-determined level, the switch is actuated and the alarm set off to signal that the carton is improperly filled. Also located adjacent collar 382 is filler requirement detecting switch 384. When probe 342 contacts the product, collar 382 contacts switch 384, which electrically stops the counting circuit. Electrically connected to the electric eye 374 is counter 386. Counter 386 accumulates the count from electric eye 374 and transmits signals representing the count to the filler system, hereinafter described, simply by reversing the counter. The top filler system, associated with the filler detector system, is also located behind the discharge table of FIG. 1 and to the right of the filler detector system. As the signal from switch 384 is actuated, the box is then moved down the discharge table to the position of the filler system. When the box reaches the proper position on the filler system, switch 400 is actuated by the carton. This turns on the filler system (FIGS. 12 and 13) and reverses the counter 386 so that signals are then passed to the filler system, and a filler is pulled from a hopper or magazine for each count or each signal given by the counter.

As shown in FIGS. 12 and 13, the filler system is mounted in a frame 402. The upper portion of frame 402 represents a filler hopper for storing the filler elements in a vertical position. Pressure is applied to the back end of the fillers by means of backup plate 404 which is actuated by spring 406. The fillers are also moved forward by means of screw. conveyors 408 driven byan appropriate motor 410. The width of fillers in the filler hopper may vary and side support bar 412 is slidably mounted in frame 402 to accommodate different widths of fillers. The front edges of the fillers are held in the hopper by means of spring-loaded pivotal knife edge 414. Resting against the filler also are suction cups 416. Suction cups 416 are mounted on suction cup support plate 418. Also pivotally connected to suction cup support plate 418 is the shaft of pneumatic on air cylinder 420. The opposite end of hydraulic cylinder 420 is pivotally mounted on support plate 422, which is attached to frame 402. Suction cup support plate 418 is pivotally attached to the frame 402 at pivot 424. Each time a signal is received from the counter, pneumatic or air cylinder 420 is actuated to pivot support plate 418 outwardly and simultaneously, suction is applied to suction cups 416. Thus, one filler is withdrawn on each signal. As the support plate 418 pivots outwardly to its maximum extent, it contacts a switch 426, which discontinues the suction of suction cups 416 and drops the filler onto curved, L-shaped chutes 428. From curved chutes 428, the filler slides downwardly and drops onto accumulating table 430. Accumulating table 430 has mounted thereon pneumatic or air cylinder 432. Attached to the forward end of cylinder 432 is pusher plate 434, of adjustable width which discharges the fillers off the accumulating table 430 and into the carton. However, this discharge does not take place until the counter reaches zero and sends a signal to actuate cylinder 432 and to deactivate cylinder 420. Accumulator table 430 is adjustable to accommodate different widths of cartons and is therefore slidable forwardly and backwardly. This is accomplished by adjusting the adjustable front half of pusher plate 434 and, also, guides on the end of chutes 428. To adjust table 430 for different height cartons, handwheel 436, which is attached to rod 438, is turned. On rod 438 is a worm which turns a worm gear 440 mounted on the same shaft 442 (rear) as two of the pinion gears 444. The other shaft 442 (front) with the gears 444 is driven by sprockets 446 and a chain 448 between the two shafts. The up and down adjustment is guided by cam follower bearings 405 on the opposite side of the gear racks 452 from the gears 444. Side to side guiding is accomplished by the gears 444 on the shafts being aligned to fit snugly between the sides of the frame 402.

To briefly summarize the operation of the machine, the following will be helpful. The machine is preferably installed at the end of a finishing operation in the paper industry. Pre-wrapped reams of paper are accepted into an indexing system which requires 2 reams to be fully into the unit prior to its automatic indexing. Once the two reams are in the proper position, they will trip a switch which will cause an air cylinder to push them forward onto a second plate. As the pusher retracts, leaving the 2 reams on the second plate, a second pusher will come down and compress the two reams that are in location and lower them approximately 1 ream height. This procedure will continue until a desired number of reams have been stacked. The purpose of the tamping cylinder is to help deaerate the packages as they are being lowered. This is of particular importance where a ream of paper or the like is not prewrapped but are instead banded into reams. Such banded reams can acquire tremendous amounts of air while going to the various indexing operations. .The tamping cylinder can be eliminated and replaced by limit switches or an electric eye to actuate and lower the stack elevator. Once the pre-determined stack has been accumulated on the stack elevator, the elevator will descend to its bottom-most position where the stack will again be indexed forward by a second pusher against a stop plate. This squares 2 edges of the reams. As soon as this has been done, the stack of packages will trip a switch on the stop plate causing the stack to be pushed forward from this position onto a casing table. As the stack is pushed onto the casing table, this pusher, together with a retractable stop plate, squares the other two edges of the reams. Cartons are stored in a folded position and vertically above the stack on the cartoning table and to the rear thereon. Just prior to the reams being pushed onto the cartoning table, a plate with several large suction cups affixed thereto, moves forward, grasps the front side of the carton and draws it forward from its storage hopper. As the carton is drawn forward, a stationary plate breaks the carton so that it is in its rectangular form as it is drawn over top the stack of reams. Thus, the case will be held in its fully open position above the stack of reams. Once this occurs, the open case will start to travel downwardly by means of a vacuum bar elevator. As soon as the downward travel begins, flap spreader fingers automatically pull three of the bottom flaps outwardly at their corners so that there is no chance of them being inside the case as the case is lowered over the reams. The flap spreaders also guide the case over the stack. These flaps are held out, until such time as the case has been fully lowered over the accumulated stack of reams. A hinged plate raises the leading flap to an outward, horizontal plane and the plate carrying the vacuum cups then extends to move the cased products from the casing table through a set of fixed flap folders, thereby folding the side flaps. Finally, the case is indexed onto a flighted indexing mechanism. The trailing flap is also in an outward, horizontal plane at this time. At this point, the vacuum take-up head releases the case, retracts and returns to its upper position to set up and break another case and come to rest until it receives a new signal that a pre-accumulated stack is in the proper position. The flighted indexing mechanism now moves the cased product at right angles to the previously-mentioned direction of movement. The case passes through a gluing mechanism which applies glue to the underside of the two horizontally disposed flaps. The two horizontally disposed flaps will then be guided down and inwardly to a closed position. The next case will be fed into position as soon as the first case is automatically discharged from the machine. At this point, the apparatus can include an optional sensor gage which will come down inside the carton, automatically determine the height to fill in the carton and automaticaly put in sufficient fillers to bring it up to the required height.

Although the machine was designed primarily for the paper industry, it is obvious that it can be utilized on any product that is reasonably stiff and maintains a rectangular or square shape. For example, acoustic tiles, butter, boxes of tea, boxes of potato chips, chocolates, air filters, etc. can readily be boxed by this type of equipment.

While specific illustrations have been set forth herein, it is to be understood that these are by way of illustration only, and numerous modifications and variations thereof will be apparent to one skilled in the art.

We claim:

1. Apparatus for cartoning a stack of generally rectangular objects comprising conveyor means for supplying said objects to be stacked, means forming a plurality of said objects into a stack, a supply of flat collapsed cartons, means for removing individual folded cartons from said supply, means for erecting each folded carton into a vertically disposed carton having top and bottom flaps open to form a tubular configuration, and means to lower the erected carton over and around said stack of articles.

2. Apparatus in accordance with claim 1 wherein the means for forming a stack of objects, comprises; means for pushing a single layer of said objects onto a stacking plate and means for lowering said plate the height of said single layer of objects each time a layer is pushed onto said stacking plate.

3. Apparatus in accordance with claim 2 wherein the means for pushing a single layer of objects is a series of overhead paddles carried by a continuous, flexible, driven, belt-type support.

4. Apparatus in accordance with claim 2, which additionally includes means for pressing downwardly on the stack of objects on the stacking plate.

5. Apparatus in accordance with claim 4 in which the means for pressing downwardly on the stack of objects operates each time a single layer of objects is pushed onto the stacking plate.

6. Apparatus in accordance with claim 1 wherein the means for lowering the carton includes the means for removing a single, folded, vertically-disposed carton from a carton supply rack.

7. Apparatus in accordance with claim 6 wherein the means for removing a folded carton includes suction means for gripping the side of said carton.

8. Apparatus in accordance with claim 6 wherein the means for removing the folded carton includes means for breaking said folded carton to form a tubular configuration with its top and bottom flaps open.

9. Apparatus in accordance with claim 6 wherein the supply rack includes means for advancing a folded carton to the removal position each time a folded carton has been removed from said rack.

10. Apparatus in accordance with claim 1 wherein the means for lowering the carton includes means for breaking at least one bottom flap outwardly and upwardly, whereby said flap assumes a generally horizontal position.

11. Apparatus in accordance with claim I wherein the means for lowering the carton includes means for spreading three flaps outwardly at the two corners at which they are adjacent one another.

12. Apparatus in accordance with claim 1, which additionally includes means for squaring the sides of the stack.

13. Apparatus in accordance with claim 12 wherein the means for squaring the sides of the stack includes at least means for squaring two sides of the stack, comprising; a table, a plate for pushing said stack onto said table and a stop plate means on the opposite side of said stack from the means for pushing the stack on said table.

14. Apparatus in accordance with claim 12 wherein the stop plate is a retractable stop plate.

15. Apparatus in accordance with claim 12 wherein the means for squaring the sides of a stack includes a second means for squaring the other two sides of the stack.

16. Apparatus in accordance with claim 15 wherein the first and second squaring means act sequentially.

17. Apparatus in accordance with claim 1, which additionally includes means for folding the bottom flaps of the carton after the carton has been lowered over the stack of objects.

18. Apparatus in accordance with claim 17, in which two of the bottom flaps are folded, and thereafter the other two bottom flaps are folded and which additionthe number of flat fillers necessary to fill the carton to a pre-determined height after the carton has been low ered over the stack of objects.

21. Apparatus in accordance with claim 1, which additionally includes means for depositing at least one flat filler on top of the stack of objects after the carton has been lowered over the stack of objects.

UN'ETED STATES PATENT @FFMZE CER'HHCATE @F @QRREUHQN Patent No. 3, 757,486 Dated September 11,, 1973 Invenmfl FEURS'IEIN, et al It is certified that error appears in the aboire-identifietl patent and that said Letters Patent are hereby corrected as shown below:

The first inventors name shoul cii be LUDWIG J. FEURS'IEIN instead of Ludwig J Feurston, A letter was fiied on Mey 22, 1973 in the us. Patent Office and a Substitute Declaration filed on June 4, 1973 settiney forth the correct spelling of inventor,

Signed and sealed this 18th day of December 1973.,

(SEAL) Attest:

EDWARD Mo FLETOEER ma RENE Do TEGTMEYER Attesting Officer Acting Commissioner of Patents 

1. Apparatus for cartoning a stack of generally rectangular objects comprising conveyor means for supplying said objects to be stacked, means forming a plurality of said objects into a stack, a supply of flat collapsed cartons, means for removing individual folded cartons from said supply, means for erecting each folded carton into a vertically disposed carton having top and bottom flaps open to form a tubular configuration, and means to lower the erected carton over and around said stack of articles.
 2. Apparatus in accordance with claim 1 wherein the means for forming a stack of objects, comprises; means for pushing a single layer of said objects onto a stacking plate and means for lowering said plate the height of said single layer of objects each time a layer is pushed onto said stacking plate.
 3. Apparatus in accordance with claim 2 wherein the means for pushing a single layer of objects is a series of overhead paddles carried by a continuous, flexible, driven, belt-type support.
 4. Apparatus in accordance with claim 2, which additionally includes means for pressing downwardly on the stack of objects on the stacking plate.
 5. Apparatus in accordance with claim 4 in which the means for pressing downwardly on the stack of objects operates each time a single layer of objects is pushed onto the stacking plate.
 6. Apparatus in accordance with claim 1 wherein the means for lowering the carton includes the means for removing a single, folded, vertically-disposed carton from a carton supply rack.
 7. Apparatus in accordance with claim 6 wherein the means for removing a folded carton includes suction means for gripping the side of said carton.
 8. Apparatus in accordance with claim 6 wherein the means for removing the folded carton includes means for breaking said folded carton to form a tubular configuration with its top and bottom flaps open.
 9. Apparatus in accordance with claim 6 wherein the supply rack includes means for advancing a folded carton to the removal position each time a folded carton has been removed from said rack.
 10. Apparatus in accordance with claim 1 wherein the means for lowering the carton includes means for breaking at least one bottom flap outwardly and upwardly, whereby said flap assumes a generally horizontal position.
 11. Apparatus in accordance with claim 1 wherein the means for lowering the carton includes means for spreading three flaps outwardly at the two corners at which they are adjacent one another.
 12. Apparatus in accordance with claim 1, which additionally includes means for squaring the sides of the stack.
 13. Apparatus in accordance with claim 12 wherein the means for squaring the sides of the stack includes at least means for squaring two sides of the stack, comprising; a table, a plate for pushing said stack onto said table and a stop plate means on the opposite side of said stack from the means for pushing the stack on said table.
 14. Apparatus in accordance with claim 12 wherein the stop plate is a retractable stop plate.
 15. Apparatus in accordance with claim 12 wherein the means for squaring the sides of a stack includes a second means for squaring the other two sides of the stack.
 16. Apparatus in accordance with claim 15 wherein the first and second squaring means act sequentially.
 17. Apparatus in accordance with claim 1, which additionally includes meAns for folding the bottom flaps of the carton after the carton has been lowered over the stack of objects.
 18. Apparatus in accordance with claim 17, in which two of the bottom flaps are folded, and thereafter the other two bottom flaps are folded and which additionally includes means for applying glue to said other two of said flaps before folding said other two flaps.
 19. Apparatus in accordance with claim 1, which additionally includes means for depositing a flat filler beneath the objects prior to lowering the carton over the stack of objects.
 20. Apparatus in accordance with claim 1, which additionally includes means for detecting and counting the number of flat fillers necessary to fill the carton to a pre-determined height after the carton has been lowered over the stack of objects.
 21. Apparatus in accordance with claim 1, which additionally includes means for depositing at least one flat filler on top of the stack of objects after the carton has been lowered over the stack of objects. 